Method of and apparatus for forming an edible product



March 12, 1968 K. BELLY r 3,372,654

METHOD OF AND APPARATUS FOR FORMING AN EDIBLE PRODUCT Filed Sept. 1 19652 Sheets-Sheet 1 J INVENTOR v N (EM/57A 5544 v BY Zn ATTORNEYS K. BELLMarch 12, 1968 METHOD OF AND APPARATUS FOR FORMING AN EDIBLE PRODUCT 2Sheets-Sheet 2 Filed Sept. 1, 1965 V C V C V V C V C V V C V C V C V C VV C V C c vicv VCVC G V 6 v; v

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United States Patent 3,372,654 METHOD OF AND APPARATUS FOR FORMING ANEDIBLE PRODUCT Kenneth Bell, Marengo, Ill., assignor to National DairyProducts Corporation, New York, N.Y. ,a corporation of DelawareFiledSept. 1, 1965, Ser. No. 484,352 7 Claims. (.Cl. 1tl71) ABSTRACT .OFTHE DISCLOSURE A method and apparatus for forming an edible product ofdifferent materials with similar sections of the ma terials arranged incontacting layers and with the sections in each layer arranged inparallel contacting rows,

each section in each row in each layer contacting at least one sectionof a different material in thesarne row, at least one section ofdifferent material in at least one adjacent row, and at least onesection of different material in at least one adjacent layer.

an edible product of the above character by a novel method and apparatuswhich are faster and insure more uniform products whencornpared withprior methods and apparatus.

Another object is to provide a novel method and apparatus in which asingle extrusion of the different materials is utilized to transfer afinished product to a container and deliver to a pattern formingapparatus all of the materials neededto form another product.

A further object is to arrange the sections of different materials ofthe rectangular block in .the finished .pattern in a novel mannerenabling the finished block to be extruded in a single operation.

A more detailed object is to form an alternating pattern of differentmaterials by substituting spaced portions of acolumn of one material forspaced portions of a column of another material.

Other objects and advantages of the invention will 'become apparent fromthe following detailed description taken in connection with theaccompanying drawings in which:

FIGURE 1 is a fragmentary sectional view vof apparatus embodying thenovel features .of the present invention, the section being taken in avertical .central plane of the apparatus;

FIG. 2 is a fragmentary sectional view taken along the line 2. 2 of FIG.1;

FIG. 3 is a fragmentary sectional view taken along the line 33 of FIG.1;

FIG. 4 is a reduced schematic plan view of the appara- FIG. 5 is aperspective view of a rectangularedible product formed by the apparatusof FIG. 1; and

FIGS. 6, 7, 8, 9, 10, 11 and 12are schematic views similar to FIG. 1 andshowing successive steps in the method of forming the edible product.

The method and apparatus of the present invention are especially suitedforthe formation of aniedihle product 3,372,654 Patented Mar. 12 1968"ice 15 made up of a plurality of sections 16 and 17 of differentmaterial arranged in contacting layers 18 with adjacent sections of eachlayer formed of different materials and adjacent sections of adjacentlayers aligned with each other transverselyjof the layers and alsoformed of ditferent materials.

In more particular aspects of the invention, the product 15 isrectangular in shape as shown in FIG. 5 with the sections 16 and 17 ofdifferent material in each layer 18 arranged in perpendicular paralleland transverse rows to form a checkerboard pattern and with a similarcheckerboard pattern appearing in vertical planes parallel to the sideand end walls ofthe block.

In general, the improved method comprises the steps of forming elongatedcolumns 19 of the different materials (FIGS. 1, 6, 8, l0 and 12), andshifting longitudinally spaced portions of the columns transversely ofthe columns to remove such spaced portions from each column, andinserting such removed portions of one column between interveningportions of an adjacent column, thereby producing a column 20 dividedinto the sections 16 and 17 adjacent ones of which are formed ofdifferent materials. These steps preferably are performed simultaneouslyon a plurality of columns 19 disposed side by side and having a lengthequal to the desired length, or in this instance, vertical dimension, ofthe finished product. After the spaced portions of each column have beenreplaced by portions of anothercolumn of different material, the columns20 of mixed materials are extruded into side by side contactingrelationship and transferred into a carton. To form the rectangular.productof FIG. 5, there are the same number of mixed columns as thereare sections in each layer of the block. In the present instance, thereare 12columns corresponding to the 12 sections of each layer arranged inthree rows of four sections each, there being four layers in theillustrated block.

The improved method ,and apparatus, although par ticularly suited forice cream of different flavors or colors, also may be employed withother products which are extruded but have sufficient viscosity toretain their shape until deposited in a container 21. Examplesof suchother products are sherbets, .ices, dough, puddings, peanut butter,cream cheese and shortenings such as margarine. Two different materialsare shown in the product of FIG. 5 as forming a checkerboard pattern ineach of three planes parallel to the sides, ends and top and bottomwalls of the block 15. However, more than two different materials may beemployed as will appear more in detail hereinafter.

The improved apparatus for practicing the method includes a housing22defining aplurality of chambers 23, 24 and 25 adapted to receive thedifferent materials of .thefinished product 15 and communicatingwithdischarge ports 26 arranged in a pattern similar to the pattern ofthe sections 16 and 17 of each layer ofqthe product, adjacent portscommunicating with different chambers as to deliver different materialsside by side. Aligned vertically with the ports :are similarly arrangedopenings 27 in a plurality of parallel plate 28 and similaropenings 27in other plates 29 which are parallel to and alternate with the firstplates 28. These plates 28 and 29 and another .plate 30 defining thedischarge ports are arranged in parallel horizontal planes and aredivided into ,two groups one of which is formed by theidischarge plate30 and the alternating plates 28. The other group is formed by theintervening plates 29. The plates 28 and 29 beneath the discharge plate30 form a stack and each of these plates is of a thickness equal to alayer 18 of the finished product 15, the openings and 27 in these platesbeing of the same rectangular cross-sectional shape as the shape of thesections 16 and 17 in each layer f the product.

The column 19 of different materials in the improved method are formedby extruding the materials from the chambers 23, 24 and 25 and throughthe discharge ports 26 into the aligned openings 27 and 27 of theforming plates 28 and 29 disposed beneath the discharge plate 30. Spacedsections of the columns are replaced by spaced sections of differentmaterials by shifting one of the aforementioned groups of platestransversely of the columns, herein horizontally, to bring differentopenings of adjacent plates and the different materials therein intovertical alignment. After such shifting of spaced portions of adjacentcolumns, the newly formed columns 20 of different materials are extrudedfrom the newly aligned openings in the stack of plates and new columnsare formed in such openings by additional material discharging throughthe ports in the discharge plate.

Following the formation of the new columns 19 each of a single material,the groups of plates 28, 29 and 30 are shifted relative to each other inthe reverse direction to bring the originally aligned openings 27 and27' back into alignment vertically. This results in the removal ofspaced sections of material from the columns 19 and insertion of theremoved sections of one column between intervening sections of theadjacent column 19. To insure the formation of a regular checkerboardpattern, that is, adjacent sections in each layer and adjacent sectionsin adjacent layers of different materials, the plates in the groupincluding the discharge plate 30 and the alternating plates 28 areformed with one more row of ports 26 or openings 27 and 27 extendingtransversely of the rows which parallel the direction of relativeshifting of the groups.

In the present instance, the housing 22 comprises a tubular verticalside wall 31 of rectangular cross section abutting at its lower endagainst the discharge plate 30 which also forms the bottom of thehousing. At its upper end, the side wall is formed with an outwardly andhorizontally projecting rim 32 which supports an upper divider plate 33and a top cover 34 of the housing, the cover being tubular and of thesame cross-sectional shape as the side wall with an outwardly projectinglower rim 35 coextensive with an overlapping the side wall rim 32 andthe periphery of the upper plate 33. The assembly made up of the covermember, upper plate, side wall and bottom plate is secured together bysuitable bolts 36 extending vertically between the bottom plate and theupper side of the rim on the cover along the outer side of the sidewall.

The upper plate 33 and the top cover 34 cooperate to define one chamber23 for one material and this is connected through a fitting 37 on thecover and a flexible tube 38 to a source 39 (FIG. 4), herein an icecream freezer, of the material. Communication between this chamber andspaced ones of the discharge ports 26 is elfected herein through theprovision of flow tubes 40 secured and extending between the upper andlower plates 30 and 33. Other fittings 41 and 42 are secured to andextend outwardly from opposite sides of the vertical side wall 31 of thehousing and are connected respectively through flexible tubes to one ormore other sources 43 and 44 again freezers in this instance, of othermaterials in the final product. In this instance, two such other sourcesare shown.

To separate materials from the second and third sources 43 and 44 andfrom the other chambers 24 and 25 for them within the housing, separatoror divider plates 46 extend between the upper and lower housing plates33 and 30 and are secured to and close the space between adjacent flowtubes 40 in the center row of these tubes and the space between the endtubes of this row and the ends of the side Wall 31. With thisarrangement, each of the other chambers is defined by the separatorplates, the upper and lower housing plates, the vertical side wall andthe flow tubes. On its lower side, the lower discharge plate 39terminates in a plane and the discharge ports 26 are in this plane andare of square cross section to correspond to the shape of the sections16 and 17 of the layers 18 in the finished product.

The relative movement between the groups of plates in this instance iseffected by supporting the intervening plates 29 of the second groupstationarily and mounting the housing with its discharge or lower plate30 and the alternating plates 28 for horizontal reciprocating movement.Such support comprises the fixed plates and a stationary horizontalsupport plate 5% which slidably receive the moving plates, thehorizontal support plate lying beneath and slidably supporting the lowermost alternating plate 28. Also, outwardly projecting horizontal ribs47 on the respective moving plates are received in grooves 43 ofcomplementary shape formed in spaced stationary guide bars 49 rigid withthe stationary plates.

The stationary plate 50 beneath the lowermost reciproeating plate 28supports the latter for sliding horizontal movement and also rigidlysupports a downwardly extending discharge tube 51. This tube isrectangular in cross section and its walls register with the edges of anopening 52 in its supporting plate and with the outermost walls of thealigned openings 27 and 27 in the fixed forming plates 29 so that, asmaterial is extruded through the discharge ports 26 and into the alignedopenings 27 and 27' in the forming plates, material already in theopenings is extruded into the discharge tube. From the tube, thematerial is extruded further into the carton 21 which is supported in anenclosing position about the downwardly opening lower end portion of thedischarge tube. At this end, the walls of the tube 51 are taperedinwardly a small amount as shown in FIG. 1 to retain the columns ofmaterials in the tube and aligned plate openings 27 and 27' as thecarton is replaced between extrusion steps.

The reciprocating plates 28 and 30 are shifted between one extremeposition in which first the ports 26 and openings of the transverse rowof such openings at one end of these plates are aligned with theopenings 27 and 27' in the stationary plates 29 and the ports andopenings of the transverse row at the other end (herein, the right end)are blocked by the stationary plates 29 and 50 as shown in FIG. 1 andanother extreme position in which the originally blocked ports andopenings are aligned with the openings in the fixed plates and the portsand openings of the transverse row at the other end are blocked. Suchreciprocation may be efiected by suitable actuating means, for example,a fluid pressure motor 53 of the piston and cylinder type having astationarily mounted cylinder and a piston Whose rod 54 is coupled tothe reciprocating plates 28 and 30. The coupling herein is a clevis 55connected by a link 56 and bolts 57 to lugs 58 secured to and projectingoutwardly from one end of the housing 22. Extensions of the bolts aresimilarly connected through links 59 to other lugs 60 projecting outwardly from the reciprocating forming plates 28 in parallel with thelugs on the housing.

Pressure fluid for actuating the piston and cylinder operator 53 isintroduced to opposite ends of the cylinder through conduits 61 underthe control of a solenoid valve 62. In this instance, it is contemplatedthat the pressure fluid be compressed air derived from a suitable source(not shown), the valve alternating connecting each end of the cylinderto the source or venting the end to atnrosphere.

In the operation of the improved apparatus, let it be assumed that noice cream is present in the forming openings 27 and 27' or the dischargetube 51 but is available in the various chambers 23, 24 and 25. Pressurethen is applied to the materials to extrude them in amounts sufficientto just fill the openings in the forming plates 28 and 29. Let it beassumed further that there are only two flavors of ice cream such asvanilla and chocolate with one supplied by one source 39 through theupper chamber 23 .and the other supplied by both of the .other sources43 and .44 through the other chambers 24 and 25. After extrusion ofthese materials in the proper amounts to just fill the forming openings,the condition of these openings will be as depicted schematically inFIG. 6, the small .vs indicating vanilla and the small cs indicatingchocolate. Itwill be seen that the discharge .ports 26 of the rightmostrow ports in the discharge plate .30 are blocked :by the uppermoststationary plate 29 and the forming openings 26 in the rightmost rows ofreciprocating forming plates 28 thus remain empty.

After the original columns 19 of the different materials are formed asshown in FIG. 6, the discharge plate 3.0 and the reciprocal formingplates 28 are shifted to the left, thereby substituting spaced portionsof the three columns to the right for corresponding portions in theadjacent three columns to the left as shown in FIG. 7. The rightmostcolumns at this time are incomplete. This shifting is followed by a.repeated extrusion of materials in amounts equal to those of thefinished product '15 to form new columns 19 each of only one material asshown in FIG. 8, the leftmost discharge ports 26 for vanilla being shutoff by the uppermost forming plate 29. In this extrusion step, thepreviously formed incomplete product of alternating sections is extrudedinto the discharge tube 51.

Following the second extrusion stop, the discharge and reciprocableforming plates 30 and 28 are reversely shifted to the right to thepositions shown in FIG. 9 to form the first completed product with allmixed columns 20 having alternating sections of chocolate and vanillathroughout their lengths. This horizontal shifting is followed byanother extrusion of the materials in amounts equal to those in thefinished product and such extrusion results in advance of the firstcompleted product into the discharge tube and the formation of newcolumns 19 each of a single material as shown in FIG. 9.

Following this step, the steps of extrusion and horizontal shifting arerepeated alternatingly, a completed product 15 being extruded into thedischarge tube and another completed rectangular block being extrudedfrom the tube after each succession of shifting and extrusion steps. Aseach completed product is discharged from the discharge tube, it isreceived in the carton 21 which is removed from the discharge tube andreplaced by an empty carton telescoped upwardly over the lower end ofthe tube.

While the invention is susceptible of various modifications andalternatives, preferred embodiments are described above and shown in thedrawings. It is to be understood, however, that the invention is notintended to be limited by such disclosure. Rather, it is the aim tocover all modifications and alternatives falling within the spirit andscope of the invention as expressed in the appended claims,

What is claimed is:

1. A method for forming an edible plastic product including twomaterials comprising the steps of forming two elongated columns of saidmaterials, simultaneously removing a plurality of portions at spacedintervals along the length of each column and inserting the portionsremoved from one column between intervening portions of the othercolumn, thereby providing a column with alternating portions of saidmaterials.

2. In a method of forming an elongated edible product of differentmaterials in contacting layers each divided into sections with adjacentsections in each layer contacting each other and formed of differentmaterials and adjacent sections of adjacent layers formed of differentmaterials and aligned transversely of the layers, the steps of extrudingsaid materials into parallel columns disposed side by side and having alength equal to the desired length of said product with adjacent columnsformed of different materials, shifting spaced portions of the columnstransversely of the columns to remove such spaced portions from thecolumns and inserting the removed portions of one column betweenintervening portions of an adjacent column to form mixed columns eachhaving sections of different materials along its length, and ,eXtrudingsaid mixed columns longitudinally of the columns and into a container.

3. In a method of forming a rectangular block of different ediblematerials in contacting layers each parallel to ends of the block anddivided into sections with adjacent sections in each layer contactingeach other and formed of different materials in a checkerboard patternand with adjacent sections of adjacent layers formed of differentmaterials and aligned transversely of the layers, the steps of extrudingsaid materials into parallelcolumns disposed side by side and having alength ,equal to the desired length of said product between said endswith adjacent columns formed of different materials, shifting spacedportions of the columns transversely of the columns to remove the spacedportions from the columns and inserting the removed portions of onecolumn between intervening portions of an adjacent column to form mixedcolumns each having sections of different materials along its length,and extruding said mixed columns longitudinally of the columns and intoside by side engagement with each other with adjacent sections ofadjacent columns formed of different materials to provide checkerboardpatterns in planes perpendicular to each .other and parallel to the flatsides of said block between said ends.

4. An apparatus for forming an edible prod-uctof different materialshaving contacting layers each divided into sections with adjacentsections within .each layer torrned of different materials and adjacentsections of adjacent layers aligned transversely of the layers andformed of different materials, the combination of a plurality of sectionforming plates arranged side by side in parallel planes to form a stackand each having a thickness equal to the thickness of one of said layersand openings corresponding in shape and arrangement to the shape andarrangement of said sections in each layer, means defining a pluralityof chambers, each adapted to contain a different material, a dischargeplate lying in a plane parallel to and closely adjacent the formingplate at one end of said stack of plates and having a plurality of portscorresponding in number and arrangement and registering with therespective openings in such end plate with adjacent ones of said portscommunicating with different ones of said chambers, said discharge plateand alternating plates of said stack constituting one group of platesand the intervening plates including said end plate constituting anothergroup, and means supporting said plates for relative movement of one ofsaid groups relative to the other group and in a direction parallel tosaid planes to shift the one group from one position of alignment of theopenings of its plates with the openings of the other group to adifferent position of such alignment.

5. An apparatus for forming an edible product of different materialshaving contacting layers each divided into sections with adjacentsections within each layer formed of different materials and adjacentsections of adjacent layers aligned transversely of the layers andformed of different materials, the combination of a plurality of sectionforming plates arranged side by side in horizontal planes to form astack and each having a thickness equal to the thickness of one of saidlayers and openings corresponding in shape and arrangement to the shapeand arrangement of said sections in each layer, means defining aplurality of chambers, each adapted to contain a different material, adischarge plate lying in a horizontal plane above and closely adjacentthe uppermost forming plate in said stack and having a plurality ofports corresponding in number and arrangement and registering with therespective openings in such uppermost plate with adjacent ones of saidports communicating with different ones of said chambers, said dischargeof section forming plates lying side by side in parallel planes to forma stack and each having a plurality of rectangular openings arranged ina checkerboard pattern in parallel and transverse rows and aligned withthe openings of the other plates transversely of said planes, each ofsaid plates having a thickness equal to the desired thickness of a layerof said product, means defining a plurality of chambers each adapted tocontain a different material, a discharge plate lying in a planeparallel to and closely adjacent the forming plate at one end of saidstack of plates and having a plurality of ports corresponding in numberand arrangement and registering with the respective openings in such endplate with adjacent ports communicating with different ones of saidchambers, said discharge plate and alternating plates of said stackconstituting a first group and each having one more of said transverserows of openings and ports than the intervening plates which includesaid end plates and constitute another group, and means supporting saidplates for relative movement of said groups in a direction parallel tosaid parallel rows of openings to bring said openings of said transverserows of said other group alternately into registry with differenttransverse rows of the first group.

7. An apparatus for forming a rectangular product of ditferent ediblematerials, the combination of a plurality of section forming plateslying side by side in horizontal planes to form a stack and each havinga plurality of rectangular openings arranged in a checkerboard patternin parallel and transverse rows and aligned vertically with the openingsof the other plates, each of said plates having a thickness equal to thedesired thickness of'a layer of said product, means defining a pluralityof chambers each adapted to contain a different material, a dischargeplate lying in a horizontal plane above and closely adjacent theuppermost one of said forming plates in said stack and having aplurality of ports corresponding in number and arrangement andregistering with the respective openings in such plate with adjacentports communicating With different ones of said chambers, said dischargeplate and alternating plates of said stack constituting one group andeach having one more of said transverse roWs of openings and ports thanthe intervening plates which includes said uppermost plate andconstitute another group, and means supporting said plates for relativemovement of said groups in a direction parallel to said parallel rows ofopenings to bring said openings of said transverse rows of said othergroup alternately into registry with different transverse rows of thefirst group.

References Cited UNITED STATES PATENTS 3,295,466 1/1967 Bell et al.10754 X WALTER A. SCI-IEEL, Primary Examiner.

I. SHEA, Assistant Examiner.

